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Simple Woodworking:Deck Bench

Parts

© Chris Hill/Chief's Shop 2011 • chiefs-shop.com

Lumber

Position one End Rail flush with the ends and edges of two End Stiles as shown here, and attach using glue and 2 1/2" pocket hole screws (PHS). Position a Short Stile centered on the End Rail and attach using glue and 2 1/2" PHS. Position another End Rail flush against the bottom of the Short Stile and attach to the End Stiles and Short Stile using glue and 2 1/2" PHS. Repeat to create a second End Assembly. Position one Side Rail on the edge of two Side Stiles and flush with one end as shown below, and attach using glue and 2 1/2" PHS. Position two Short Stiles on the Side Rail as shown below and attach using glue and 2 1/2" PHS. Position another Side Rail flush against the bottom of the Short Stiles and attach to the Side Stiles and Short Stiles using glue and 2 1/2" PHS. Repeat to create a second Side Assembly.

Note: Set your Kreg jig and bit for 1 1/2" stock.

Drill the holes 3/4" from the outside edges,

except on one end of the Short Stiles - drill

those holes 1" from the outside edges.

End Stile

Short Stile

End Rail

Side Rail

Side Stile

Short Stile Side

RailShort Stile


Position the End Assemblies flush with the outside edge of the Side Assemblies as shown, and attach using glue and 2 1/2" deck screws. Drive the screws through the End Stiles and into the Side Stiles (use at least four screws at each joint - 16 total).


End Assembly

Side Assembly



End Cleat

Stretchers

Side Cleat

Position the End Cleats flush against the bottom edge of the End Rails as shown, and attach using glue and 2 1/2" deck screws. Drive the screws through the End Cleats and into the End Rails (use at least four screws per Cleat).

Position the Side Cleats flush against the bottom edge of the Side Rails and End Cleats as shown, and attach using glue and 2 1/2" deck screws. Drive the screws through the Side Cleats and into the End Rails (use at least six screws per Cleat).

Position the Stretchers as shown above and attach to the Side Cleats using glue and two 2 1/2" PHS on each end.

Place the Bottom Panels on top of the Cleats and attach using glue and 1 1/4" deck screws. Drive the screws through the Panels and into the Cleats. It will help to mark the position of the Cleats on the Panels prior to placing them inside the assembly.

Place the bottom Side Panels flush against the Bottom Panels and the inside of the assembly and attach to the Side Assemblies using glue and 1 1/4" deck screws. Drive the screws through the Panels and into the Side Rails, Side Stiles, and Short Stiles. Place the top Side Panels flush against the top edge of the the bottom Side Panels and the inside of the assembly and attach to the Side Assemblies using glue and 1 1/4" deck screws. Drive the screws through the Panels and into the Side Rails, Side Stiles and Short Stiles.

Place the bottom End Panels flush against the Bottom Panels, Side Panels, and inside of the assembly and attach to the End Assemblies using glue and 1 1/4" deck screws. Drive the screws through the Panels and into the End Rails, End Stiles, and Short Stiles. Place the top End Panels flush against the top edge of the the bottom End Panels and the inside of the assembly and attach to the End Assemblies using glue and 1 1/4" deck screws. Drive the screws through the Panels and into the End Rails, End Stiles and Short Stiles.



Bottom Panel

Side Panels

End Panel



Position the Lid Rails flush with the inside edge of the face of the Lid Stiles and attach using glue and 1 1/4" PHS to create the frame for the lid. Use two PHS on each end of the Lid Rails.

Position the Lid Stretchers flush with the bottom edge of the Lid frame and spaced as shown above and attach to the Lid Stiles using glue and 1 1/4" PHS.

Check the inside dimension of the Lid frame and make adjustments to the Lid Panel dimensions if needed. Place the Lid Panels as shown below and attach to the Lid Stretchers using glue and 1 1/4" deck screws. Drive the screws through the Lid Stretchers and into the Lid Panels. Also drive screws through the Lid Rails and into the ends of the Lid Panels.

Lid Rail

Lid Stile

Lid Stretchers

Lid Panels

Note: Set your Kreg jig and bit for 3/4" stock.



Attach the Lid to the body using galvanized extra heavy duty "T" hinges. Lowe's carries them - look for item #102892 (about $10 per pair).

Heavy-duty lid supports are strongly recommended, especially if small children will be around this project.


Cutting DiagramNote: Use cedar or redwood for the 1 x material, and treated, cedar, or redwood for the 2 x material.

Follow ALL SAFETY GUIDELINES AND RECOMMENDATIONS provided by the manufacturers of your tools, and any chemicals such as glue and

finishes you use in this project. YOU are responsible for your safety, so use common sense when working in the shop!


2 x 4 x 8

2 x 4 x 8

1 x 8 x 10

2 x 4 x 8

2 x 4 x 8

2 x 4 x 8

2 x 2 x 8

1 x 6 x 8

1 x 6 x 10

1 x 6 x 10

1 x 6 x 10

1 x 3 x 8

1 x 2 x 8

1 x 2 x 8

lumber simple woodworking: deck bench · simple woodworking: deck bench attach the lid to the body...

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